NCCCO Crane Inspector cheat sheet

Wire rope removal criteria (ASME B30.5): 12 randomly distributed broken wires in 6 rope diameters, or 4 broken wires in one strand in 6 diameters; 6 broken wires in 30 diameters; kinking, crushing, bird-caging, or corrosion pitting requires removal.

Sheave inspection: groove wear is excessive when the groove diameter exceeds the nominal rope diameter by more than 5% for running ropes; sheave flange wear is excessive when the flange is less than 50% of its original thickness.

Hook inspection: a hook must be removed from service if the throat opening increases more than 15% of its original dimension, if wear exceeds 10% of the original cross-section, or if the hook has more than 10 degrees of twist from the plane of the unbent hook.

Sling inspection (ASME B30.9): remove a chain sling when wear exceeds 15% of link stock diameter or when the chain has stretched more than 5% of its original length; remove a wire rope sling per the broken-wire criteria for the rope diameter used.

Structural welds: inspect for cracks, especially at the boom pivot, gantry, and turntable connections; a crack in a primary load-bearing weld is a removal-from-service condition until repaired per the manufacturer's or an engineer's instructions.

Hydraulic system: check cylinder rods for scoring, pitting, and bent rods; check hoses for abrasion, blistering, and leaks; a leaking hydraulic hose on a load-holding circuit is a removal-from-service condition.

Outrigger and float inspection: verify outrigger beams extend and lock, pads are not cracked or deformed, and floats are sized per the load chart; outrigger beams with cracked welds or bent sections must be removed from service.

Anti-two-block device: must be functional and tested each shift; a non-functioning anti-two-block is a removal-from-service condition because it prevents rope and boom damage.

Boom inspection: check for bent or cracked chords, lattice damage, and loose or missing pins and keepers; boom sections with bent chords or cracked welds require engineering evaluation before continued use.

Load moment formula: Load Moment = Load Weight x Load Radius; the load moment plus the machine's moment must remain within the crane's rated capacity at that radius.

Rated capacity is the lower of the structural limit and the stability limit; the load chart value must be reduced for configurations not covered by the chart (e.g., non-standard outrigger spread, side loading).

Net capacity = gross capacity from the load chart minus the weight of all lifting attachments (hook block, slings, spreader bar, and any below-the-hook device).

ASME B30.5 requires that the load not exceed the rated capacity; the operator must verify the load weight and radius before each lift, and a load chart must be available in the cab.

Two-crane (tandem) lifts: each crane's share of the load must not exceed 75% of its rated capacity at the working radius unless the lift is engineered and approved; the load must be kept within the cranes' combined stability envelope.

Personnel lifting: only with a crane and platform designed and approved for personnel, with a pre-lift meeting, a trial lift, and a fall-protection system; the platform must have a gate and the operator must maintain communication.

Wind: the manufacturer's load chart wind limit (often 20 mph or less for large booms) governs; when wind speed exceeds the limit, the lift must stop and the boom must be lowered or the crane secured per the manufacturer.

Ground bearing: outrigger float pressure = total crane plus load weight divided by the total float bearing area; the supporting surface must be verified to have adequate bearing capacity before setup.

Signal systems: hand signals, voice, or radio per ASME B30.5; a signal person must be used when the operator cannot see the load or the load path, and only one signal person may direct the operator at a time.

Load chart verification: the load chart in the cab must match the crane model, boom configuration, and outrigger configuration; a missing or mismatched chart is a removal-from-service condition.

Annual inspection: ASME B30.5 requires a documented annual inspection by a qualified person, covering structural, mechanical, electrical, and hydraulic components, with records retained.

Frequent inspection: required monthly to quarterly depending on severity of use, covering the items listed in the manufacturer's manual and ASME B30.5, with written records.

Periodic inspection: required annually to biennially depending on severity of use, including disassembly of components as needed to inspect for wear and cracks.

Pre-shift inspection: the operator must perform and document a pre-shift inspection each shift, checking controls, brakes, limit switches, and safety devices before use.

OSHA 29 CFR 1926.1412 requires annual and periodic inspections by a qualified person, and 1926.1413 requires wire rope inspections at specified intervals; records must be available for review.

Proof load testing and certification: verify the crane has a current load test certificate where required by the jurisdiction, and that the test was performed at the rated capacity or as specified.

Operator and inspector qualifications: verify the operator holds a valid certification (e.g., NCCCO) for the crane type and the inspector is a qualified person as defined by ASME B30.5 and OSHA.

Fire extinguisher, seat belt, and access: verify the crane is equipped with a fire extinguisher, seat belt, and safe access ladders and steps per OSHA 1926.1411 and 1926.1412.

Inspection report content: crane make, model, serial number, hour meter reading, date, inspector name and qualification, items inspected, findings, and corrective actions with target dates.

Deficiency classification: categorize findings as (a) removal from service, (b) repair before next use, (c) monitor at next inspection, or (d) no action; the classification drives the disposition and re-inspection interval.

Documentation retention: inspection records must be retained per the manufacturer's manual and applicable regulations; OSHA requires records to be available for the duration specified (commonly the current and prior inspection cycle).

Non-destructive testing: when cracks are suspected in critical welds or pins, require magnetic particle or dye penetrant testing by a qualified NDT technician, and document the test method and results.

Repair and re-inspection: after any structural repair, the crane must be re-inspected and, where required, re-tested to the original rated capacity before return to service.

Load test documentation: record test load weight, radius, configuration, and results; a load test certificate must be signed by the person conducting the test and retained with the crane records.

Corrective action tracking: each deficiency must have an assigned responsible person, a due date, and a verification of completion; open removal-from-service items must be locked out and tagged until cleared.

Photo and measurement evidence: include photographs and measured values (e.g., wire rope diameter, hook throat opening, sheave groove depth) in the report to support the disposition and to compare against future inspections.